# US 9,751,192 B2 · Polymer impregnated backing material, abrasive articles incorporating same, and processes of making and using > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,751,192 B2 - Document ID: US9751192B2 - Status: Granted - Kind: B2 - Application number: 14/857,470 - Filed: 2015-09-17 - Published: 2016-03-17 - Granted: 2017-09-05 - Earliest claimed: 2014-09-17 - Assignees: Saint-Gobain Abrasives, Inc.; Saint-Gobain Abrasifs - Applicants: Saint-Gobain Abrasives, Inc.; Saint-Gobain Abrasifs - Inventors: Muthukrishnan Sharmila; Adiseshaiah K. Sathyanarayanaiah; Frank J. Csillag; Srikant Gollapudi; Gururajan Balasubramaniam; Dibbur Narasimha Murthy Rao Manjunatha; Akhilesan Sasidharan; Akshay Ramesh; Shyam Prasad Komath; VelliamKattupudur Samiappan Naveen - Web page: https://patentgrep.com/patent/US9751192B2 ## CPC - B24D 11/02: Backings, e.g. foils, webs, mesh fabrics - B24D 11/005: {Making abrasive webs} - B24D 18/0027: {by impregnation} - D06M 15/21: Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds - D06M 15/41: Phenol-aldehyde or phenol-ketone resins - D06N 3/0011: {using non-woven fabrics} - D06N 3/12: with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds {, e.g. gelatine proteins} - D06N 3/186: {one of the layers is on one surface of the fibrous web and the other layer is on the other surface of the fibrous web} - D06M 2101/06: cellulosic - D06N 2209/1628: Dimensional stability - B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11) - D06M: TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS - D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR ## Abstract This invention relates to composite backing materials (e.g., polymer impregnated nonwoven fabrics) and coated abrasive articles that include such composite backing materials. This invention also relates to methods of making and using said composite backing materials and coated abrasive articles. The claimed processes and systems related to the use and manufacturing of coated abrasive articles are improved and cost effective. ## Claims ### Claim 1 A composite backing material comprising: a nonwoven stitch bonded fabric impregnated with a first polymer composition, a frontfill layer disposed on a first side of the nonwoven fabric; and a backfill layer disposed on a second side of the nonwoven fabric, wherein the first polymer composition comprises a combination of a first phenolic resole resin and a second phenolic resole resin, and wherein the first polymer composition cured comprises: about 40 wt % to 60 wt % of the first phenolic resole resin; and about 40 wt % to 60 wt % of the second phenolic resole resin. ### Claim 2 (depends on 1) The composite backing material of claim 1, wherein the front fill layer comprises a second polymeric composition comprising a first phenolic resole resin and a second phenolic resole resin. ### Claim 3 (depends on 2) The composite backing material of claim 2, wherein the second polymeric composition further comprises a filler. ### Claim 4 (depends on 3) The composite backing material of claim 3, wherein the second polymeric composition cured comprises: about 15 wt % to 30 wt % of the first phenolic resole resin; about 40 wt % to 55 wt % of the second phenolic resole resin; and about 25 wt % to 40 wt % filler. ### Claim 5 (depends on 1) The composite backing material of claim 1, wherein the back fill layer comprises a third polymeric composition comprising an acrylic latex resin. ### Claim 6 (depends on 5) The composite backing material of claim 5, wherein the third polymeric composition further comprises a phenolic resole resin. ### Claim 7 (depends on 6) The composite backing material of claim 6, wherein the third polymeric composition further comprises a filler. ### Claim 8 (depends on 7) The composite backing material of claim 7, wherein the third polymeric composition cured comprises: about 40 wt % to 62 wt % of an acrylic latex resin; about 12 wt % to 20 wt % of a phenolic resin; and about 25 wt % to 40 wt % filler. ### Claim 9 (depends on 1) The composite backing material of claim 1, wherein the stitch bonded fabric has a tensile strength in the machine direction and in the cross direction of not less than 15 Kg/25 mm. ### Claim 10 (depends on 1) The composite backing material of claim 1, wherein the composite backing material has a tensile strength in the machine direction in a range of 60 Kg/25 mm to 160 Kg/25 mm. ### Claim 11 (depends on 1) The composite backing material of claim 1, wherein the backing material has a tensile strength in the cross direction in a range of 50 Kg/25 mm to 110 Kg/25 mm. ### Claim 12 (depends on 1) The composite backing material of claim 1, wherein the composite backing material has a flexural modulus in the machine direction in a range of 1 GPa to 7 GPa. ### Claim 13 (depends on 1) The composite backing material of claim 1, wherein the backing material has a flexural modulus in the cross direction in a range of 0.5 GPa to 5 GPa. ### Claim 14 (depends on 1) A coated abrasive article comprising: a composite backing material according to claim 1; and an abrasive layer disposed on the composite backing material. ### Claim 15 (depends on 14) The abrasive article of claim 14, wherein the abrasive article has not greater than a 50% decrease of maximum load at 130° C. compared to room temperature. ### Claim 16 (depends on 14) The abrasive article of claim 14, wherein when the abrasive article is placed in a climate chamber at a temperature of 50° C. and 25% relative humidity (RH) for 2.5 hours has a % weight gain of less than 5.5%. ### Claim 17 A composite backing material comprising: a nonwoven stitch bonded fabric impregnated with a first polymer composition, a frontfill layer disposed on a first side of the nonwoven fabric; and a backfill layer disposed on a second side of the nonwoven fabric, wherein the first polymer composition comprises a combination of a first phenolic resole resin and a second phenolic resole resin, and wherein the back fill layer comprises: about 40 wt % to 62 wt % of an acrylic latex resin; about 12 wt % to 20 wt % of a phenolic resin; and about 25 wt % to 40 wt % filler. ### Claim 18 A composite backing material comprising: a nonwoven stitch bonded fabric impregnated with a first polymer composition, a frontfill layer disposed on a first side of the nonwoven fabric; and a backfill layer disposed on a second side of the nonwoven fabric, wherein the first polymer composition comprises a combination of a first phenolic resole resin and a second phenolic resole resin, wherein the front fill layer comprises a second polymeric composition comprising about 15 wt % to 30 wt % of a first phenolic resole resin; about 40 wt % to 55 wt % of a second phenolic resole resin; and about 25 wt % to 40 wt % of a filler.